JP2002225074A - Manufacturing method for laminated body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a laminated body wherein a surface skin material layer, an expanded thermoplastic elastomer layer which becomes a cushioning layer, and an expanded thermoplastic resin layer which becomes a base material are laminated and integrated, and also, which is light-weight and is excellent in soft feeling, of which the appearance is favorable, and which can freely cope with various design properties. SOLUTION: This manufacturing method for the laminated body is constituted of processes (1) through (6). In the process (1), a thermoplastic resin under a molten state containing a foaming agent is filled from a first molten resin-feeding port 3 into a cavity formed of a male die (A) and a female die (B). Also, a through port is formed simultaneously with the filling of the thermoplastic resin. In the process (2), the thermoplastic resin under the molten state is expanded. In the process (3), the thermoplastic resin is cooled and solidified in the dies. In the process (4), the female die (B) is exchanged with a female die (C) for molding the cushioning layer. In the process (5), a thermoplastic elastomer under a molten state, containing an foaming agent, is fed from a second molten resin-feeding port 4 of the male die (A) through the through port, and the surface skin layer and the thermoplastic resin layer are welded, laminated and integrated. In the process (6), the female die (C) is opened, and the thermoplastic elastomer under the molten state is expanded and solidified.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for producing a laminate comprising a skin layer, a foamed thermoplastic elastomer layer serving as a cushion layer, and a foamed thermoplastic resin layer serving as a substrate layer.

[0002]

2. Description of the Related Art Hitherto, a laminate in which a thermoplastic resin is used as a base material layer, and a skin layer having a cushion layer is laminated on the base material layer is well known.
JP-A-134803 and JP-A-6-234133 disclose a method of laminating a core material and a cushion skin layer simultaneously with molding.

However, according to the methods disclosed in these publications, a skin layer having a core material layer and a cushion layer can be laminated and integrated at the same time as molding, but at the time of molding, the foamed cushion layer comes into contact with a mold and is cooled. Since the solidified part is used as the skin layer, the poor appearance of the surface tends to be the same as the poor appearance of the product, and it is difficult to freely change the design of various patterns and colors as the product. there were.

[0004]

SUMMARY OF THE INVENTION
The present inventor has solved such a problem, has a good appearance,
Moreover, as a result of studying a method of manufacturing a laminate that can easily cope with the design properties such as the pattern and color of the surface, the present invention has been achieved.

[0005]

According to the present invention, there is provided a first molten resin supply port for supplying a molten foamed thermoplastic resin serving as a base material layer and a molten foamed thermoplastic elastomer serving as a cushion layer. Using a male mold (A) having a second molten resin supply port, a female mold (B) for molding a base layer, and a female mold (C) for molding a cushion layer, comprising a thermoplastic elastomer in the skin layer. A method for producing a laminate in which a foamed cushion layer is welded and integrated, and the foamed cushion layer and a foamed thermoplastic resin layer serving as a substrate are welded, laminated and integrated, (1) a male mold (A) And a foaming agent-containing molten thermoplastic resin is supplied from a first molten resin supply port into a cavity formed by the mold and the female mold (B), and is filled into the cavity and at the same time at a position of the second molten resin supply port. Corresponding melting heat containing blowing agent Step of forming a through-hole in the thickness direction of the plastic resin layer (2) After completion of the shaping, the male and female molds are opened in a state where the blowing agent-containing molten thermoplastic resin is not solidified, and the through-hole is formed. (3) cooling and solidifying the foamed thermoplastic resin layer in a mold while maintaining the foaming agent-containing molten thermoplastic resin while maintaining the above conditions. (4) converting the foamed thermoplastic resin layer into a male mold (A). ), While removing the female mold (B), and replacing the skin layer with a female mold (C) for forming a cushion layer in which the skin layer is retained in the mold product shape part. (5) Foaming retained in the male mold (A) The foamed thermoplastic resin is supplied from the second molten resin supply port of the male mold (A) into a cavity formed by the formed thermoplastic resin layer and the skin layer held by the cushion mold female mold (C). Melting heat containing foaming agent through through holes formed in resin layer A step of supplying a plastic elastomer, filling the cavity, and simultaneously welding and laminating the skin layer and the foamed thermoplastic resin layer with the thermoplastic elastomer. (6) The foaming agent which becomes a cushion layer after completion of shaping The male mold (A) and the female mold (C) for forming a cushion layer are opened in a state where the contained molten thermoplastic elastomer is not solidified, and the step of foaming the molten thermoplastic elastomer is performed. (7) Cooling and solidifying It is an object of the present invention to provide a method for manufacturing a laminate, comprising a step of opening a rear mold and removing a laminated molded product from the mold.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described specifically. As shown in a cross section in FIG. 9, the laminate (16) aimed at by the present invention has a base resin layer made of a foamed thermoplastic resin, a cushion layer made of a foamed thermoplastic elastomer, and a skin material. It is a laminate that is sequentially laminated.

The thermoplastic resin for forming the foamed base resin layer applied to the present invention is not particularly limited, and thermoplastic resins generally used in compression molding, injection molding, extrusion molding, etc., for example, polypropylene, Olefin resins such as polyethylene, polystyrene, acrylonitrile
Examples thereof include styrene-based resins such as butadiene-styrene copolymers, acrylonitrile-styrene copolymers, polyamide resins such as nylon, polycarbonates, and acrylic resins. Such thermoplastic resins may be used alone. More than one kind of mixed resin or a polymer alloy using them may be used.If necessary, talc, an inorganic filler such as calcium carbonate, a reinforcing material such as glass fiber, an elastomer for improving impact, an antioxidant, a pigment, Various commonly used additives such as a lubricant and an antistatic agent may be appropriately compounded. Among these thermoplastic resins, a propylene-based resin is preferred in terms of excellent moldability and lightness, and the propylene-based resin may be a propylene homopolymer or a copolymer with another olefin such as ethylene. It may be united.

The thermoplastic elastomer used as the cushion layer in the present invention is not particularly limited, but an olefin elastomer is preferably used.

[0009] Both the thermoplastic resin serving as the base material and the thermoplastic elastomer serving as the cushion layer are used as a foaming material to which a foaming agent is added, and the foaming agent used for such purpose is a thermoplastic resin. Or a known chemical foaming agent used when producing a foam of a thermoplastic elastomer. Specific chemical blowing agents include
Inorganic blowing agents such as sodium bicarbonate, ammonium bicarbonate and ammonium carbonate; nitroso compounds such as N, N'-dinitrosopentamethylenetetramine; azo compounds such as azodicarbonamide and azodisisobutyronitrile;
Foaming agents such as sulfonyl hydrazides such as benzenesulfonyl hydrazide, toluene sulfonyl hydrazide, diphenyl sulfone-3,3'-disulfonyl hydrazide, and p-toluenesulfonyl semicarbazide; and, if necessary, salicylic acid, urea and foaming containing these. The addition of auxiliaries is a preferred mode of use.

The type of the foaming agent is selected in consideration of the melting temperature of the thermoplastic resin and thermoplastic elastomer to be used, the desired expansion ratio, and the like. In general, the amount is 0.1 to 5 parts by weight based on 100 parts by weight of the resin.

In addition to the chemical foaming agent, liquid or gaseous carbon dioxide or nitrogen can be used as the foaming agent. In this case, these can be directly added to the molten thermoplastic resin or thermoplastic elastomer. Used by injection.

In the method of the present invention, as the skin material, any material can be used without particular limitation as long as it can be preformed into a product shape in advance. Specific skin materials include woven fabric, non-woven fabric,
Examples thereof include a sheet or a film formed of a knitted fabric, a thermoplastic resin and a thermoplastic elastomer, and a product obtained by subjecting such a skin material to various thermoforming such as vacuum forming, pressure forming, vacuum / pressure forming, or press forming. In the case of a thermoplastic resin or a thermoplastic elastomer, a product preformed into a product shape by powder molding can be used. Such skin materials can be used alone or as a stack of two or more. In addition, the surface of these skin materials may be decorated with an uneven pattern such as a grain, printing, dyeing, or the like in order to correspond to various designs.

Hereinafter, a method for producing a laminate in which such a skin material, a cushion layer made of a foamed thermoplastic elastomer, and a foamed base material layer made of a foamed thermoplastic resin are sequentially laminated will be described. In carrying out the method of the present invention, a first molten resin supply port for supplying a foaming agent-containing molten thermoplastic resin for forming a base material layer, and a foaming agent containing for forming a cushion layer are provided. A mold comprising a male mold (A) having a second molten resin supply port for supplying a molten thermoplastic elastomer, a female mold (B) for molding a base layer, and a female mold (C) for molding a cushion layer. Is used.

FIG. 1 is a schematic sectional view showing an example of a mold used in the step of forming a foamed base resin layer in the method of the present invention. The mold used in this process is
A male mold (A) and a female mold (B) for molding a base material layer. The male mold (A) has a first molten resin passage for supplying a blowing agent-containing molten thermoplastic resin into the mold. (1) and second molten resin passages (2) for supplying a foaming agent-containing molten thermoplastic elastomer serving as a cushion layer into the mold are provided independently of each other.
At the end of 2), a first molten resin supply port (3) and a second molten resin supply port (4) which are open to the cavity surface in communication therewith are provided. The above-mentioned molten resin passages are connected to respective resin feeders (not shown) provided outside the mold.

The first and second molten resin supply ports do not need to be one. Depending on the size and shape of the cavity, the molten resin supply port may be appropriately branched to form two molten resin supply ports. More than one may be provided.

The female mold (B) for forming a base material layer is used for forming a foamed base material layer in a laminate.
The mold has a shape suitable for forming a foamed base material layer. After the foamed base material layer is formed, the mold is separated from the male mold (A), and is used for forming a foamed cushion layer described later. Female type (C).

In the female mold (B) for molding a base material layer, a through hole is formed in the foamed base material layer at the same time as molding at a position facing the second molten resin supply port (4) of the male mold (A). A movable block (5) for opening is provided. The movable block (5) slides in the female mold (B) in the mold opening / closing direction so as to protrude in the mold surface direction of the male mold (A). For example, it is performed by a hydraulic cylinder or an air cylinder.

The through hole (12) formed in the foamed base material layer (9) by the movable block (5) is formed between the upper surface of the foamed base material layer formed earlier and the female mold (C) for forming the cushion layer. The through hole (12) is provided for supplying the blowing agent-containing molten thermoplastic elastomer from the second molten resin supply port (4) between the second molten resin supply port (4) and the surface. ), It is necessary to form the movable block (5) at the position of the second molten resin supply port (4), and at the same time, the foaming agent-containing molten thermoplastic resin. During supply, the top end covers the second molten resin supply port (4), and the supply port (4) is connected to the distal end face of the movable block (5) so as not to be blocked by the molten thermoplastic resin. It is necessary to keep the mold surface of A) in contact. Of course, when a plurality of second molten resin supply ports (4) are provided, a movable block (5) is provided corresponding to each supply port.

Such a movable block (5) is usually in the form of a column having the same size at the tip portion and the root portion, and its cross-sectional shape is arbitrary. The cross-sectional area depends on the opening area of the second molten resin supply port (4), but is preferably about 10 to 1000 mm2. If the cross-sectional area is too small, the cross-sectional area of the formed through-hole also becomes small accordingly. In particular, if it becomes extremely smaller than the opening area of the second molten resin supply port (4), the supply port (4) It becomes difficult for the supplied molten thermoplastic elastomer containing a foaming agent to pass through the through-holes. On the other hand, if the cross-sectional area is too large, the rigidity of the base member decreases, which is not preferable.

Therefore, the movable block (5) closes the opening of the second molten resin supply port (4) and facilitates the passage of the blowing agent-containing molten thermoplastic elastomer through the formed through hole (12). For the sake of smoothing, the second molten resin supply port (4) has a cross-sectional shape similar to that of the second molten resin supply port (4), and its cross-sectional area is substantially the same as or slightly larger than the opening area of the second molten resin supply port (4). preferable.

Since the movable block (5) is for forming the through hole (12) in the foamed base material layer (9) formed earlier, if this object can be achieved,
Any means other than the movable block can be used.

FIG. 5 is a schematic sectional view showing an example of a cushion-forming female die (C) for forming a foamed cushion layer. This female mold (C) is used in place of the female mold (B) for forming a base material layer in order to form a foam cushion layer after forming a foam base material layer and obtain a final laminate. It is.

In the female mold (C), a foamed thermoplastic elastomer layer serving as a cushion layer is formed while the skin layer (11) manufactured in a separate step is held in the mold, and the female mold (C) is formed in the previous step. This is for laminating the molded foam base material layer (9) and simultaneously integrating the skin layer and the cushion layer held in the mold, and after forming the foam base material layer. It is used in place of the female mold (B) for forming the base material layer, and has a mold shape which is different from the female mold (B) for forming the base material layer so as to be a final product shape.

In the example of FIG. 5, a peripheral slide block (10) for holding the skin layer (11) is provided at a position corresponding to the female terminal of the female type (C) so as to cover the entire circumference of the product. Have been. The slide block (10) is slidable in a direction perpendicular to the movable direction of the female mold (C), and the block (10) is moved toward the center of the mold.
To perform molding with the skin material terminal being held by the parting surface of the female mold (C) and the block surface, and after the molding is completed, the block (10) is moved outside the mold. The product is taken out.

Next, an example of manufacturing a laminate using such a mold will be described. First, female mold for base layer molding (B)
And the male mold (A) are used to bring the two molds closer to a predetermined position, and then the blowing agent-containing molten thermoplastic resin (7) is supplied from the first molten resin supply port (3) between the two molds. The molten thermoplastic resin is supplied into the cavity (6) formed as shown in FIG. 2 (FIG. 2), and the cavity is filled with the molten thermoplastic resin (FIG. 3). This mold clamping may be started at the same time as the supply of the blowing agent-containing molten thermoplastic resin into the cavity, or may be started before the supply of the blowing agent-containing molten thermoplastic resin is completed, and While the supply of the thermoplastic resin and the mold clamping are performed in parallel, the mold clamping may be completed simultaneously with or after the completion of the supply of the resin.

The thickness of the foaming agent-containing molten thermoplastic resin layer (8) in a state filled in the mold cavity, that is, the cavity clearance when the foaming agent-containing molten thermoplastic resin is filled in the mold cavity. Can be arbitrarily adjusted by the amount of thermoplastic resin to be supplied,
If the thickness is too thin, the cooling in the mold proceeds too much and it is difficult to obtain sufficient foaming in the next step, and if it is too thick, the merit of weight reduction is reduced. preferable.

After the molten thermoplastic resin containing the foaming agent is filled in the mold cavity, the male and female molds are opened while the molten thermoplastic resin is in a non-solidified state, and the mold clamping pressure is reduced to melt the resin. The foaming gas trapped in the thermoplastic resin is released and foamed to obtain a foamed base material layer (9). (FIG. 4)

At this time, the foaming agent-containing molten thermoplastic resin layer (8) filled in the cavity no longer foams by opening the mold after it is solidified, and a foam cannot be obtained. After filling the foaming agent-containing molten thermoplastic resin (7) into the cavity, it is necessary to open the mold before the molten thermoplastic resin layer (8) is completely solidified.

The opening amount of the mold is appropriately determined depending on the desired expansion ratio, but is usually 0% of the thickness of the foaming agent-containing molten thermoplastic resin layer (8) filled in the mold cavity before foaming. It is about 1 to 5 times.

After the mold is opened to foam the foaming agent-containing molten thermoplastic resin layer (8), it is cooled and solidified by the mold, and then the foamed base material layer (9) is formed. ) Is retained in the male mold (A), and the female mold (B) is separated from the male mold (A). As a result, the formed foamed base material layer (9) remains on the molding surface of the male mold (A).

In the process of forming the foamed base material layer (9), the female mold (B) is provided during the process from supply of the blowing agent molten thermoplastic resin (7) to shaping, foaming and cooling. The movable block (5) is moved forward to the molding surface side of the male mold (A), and the tip of the movable block (5) is moved to the second molten resin supply port (4) provided in the male mold (A). The movable block is not filled with the molten thermoplastic resin (7) by contacting the movable block (5), and the movable block (5) is moved backward after the completion of the cooling, thereby forming the foam. A through hole (12) is formed in the base material layer (9) at the position of the second molten resin supply port (4) in the thickness direction of the foamed base material layer.

Next, the female mold (C) for forming the cushion layer is replaced with the female mold (B). (FIG. 5) On the cavity surface of the female mold (C) for molding a cushion layer, a skin material (11) serving as a product design surface preliminarily shaped into a cavity shape is held. In the case of FIG. 5, the skin material is held by a slide block (10) forming an undercut portion.

A cushion layer (15) is formed by a female mold (C) for molding a cushion layer holding a skin material (11) in a cavity and a male mold (A) holding a foam base material layer (9). The skin material (1) is provided by the cushion layer (15).
1) and the foamed base material layer (9) are laminated and integrated.

In the laminating step, as shown in FIG. 6, the female mold (C) and the male mold (A) for forming the cushion layer, the skin material (11) and the foamed base material layer (9) are held respectively. After closing both molds in a range where the cavity clearance is larger than the final product thickness, from the second molten resin supply port (4),
The molten thermoplastic elastomer (13) containing a foaming agent is introduced into the cavity formed by the skin material (11) and the foamed base material layer (9) through the through holes (12) formed in the foamed base material layer (9). Supply.

Next, the above-mentioned cavity is filled with a foaming agent-containing molten thermoplastic elastomer by mold clamping. (FIG. 7) This mold clamping may be started at the same time when the supply of the blowing agent-containing molten thermoplastic elastomer into the cavity is completed, as in the case of forming the foamed base material layer (9). Mold clamping is started before the supply of the melted thermoplastic elastomer containing the agent is completed, and while the supply of the molten thermoplastic elastomer and the mold clamping are performed in parallel, the mold clamping is completed simultaneously with or after the completion of the supply of the elastomer. May be.

The thickness of the foaming agent-containing molten thermoplastic elastomer layer (14) filled in the cavity can be arbitrarily adjusted by the amount of the supplied thermoplastic elastomer. Similarly, if the thickness is too large, the effect of reducing the weight is impaired, so it is usually preferable to adjust the thickness in the range of about 0.5 mm to 5 mm.

After forming the foaming agent-containing molten thermoplastic elastomer layer (14), the male and female molds are opened while the molten thermoplastic elastomer is in a non-solidified state, and the mold clamping pressure is reduced to reduce the melting. The foaming gas trapped in the thermoplastic elastomer is released and foamed to form a foamed thermoplastic elastomer layer (15) serving as a cushion layer. (FIG. 8)

The opening amount of the mold is appropriately determined depending on the desired expansion ratio, and is usually about 0.1 to 5 times the thickness of the molten thermoplastic elastomer layer (14) before foaming.

After the foamed thermoplastic elastomer layer (15) is formed, it is cooled and solidified while maintaining this state, or is cooled by slightly reducing the opening amount of the foamed mold. By opening and taking out the laminate (16) from the mold, an intended laminate in which the skin material, the cushion layer and the foamed base material layer are laminated is obtained. (FIG. 9)

The injection compression molding method has been described above.
In the case of manufacturing by an injection molding method, a step of supplying a molten thermoplastic resin serving as a base material containing a foaming agent and a molten thermoplastic elastomer containing a foaming agent into a cavity is performed in advance with a predetermined cavity clearance. What is necessary is just to supply and fill resin in the state clamped so that it may become.

[0041]

According to the method of the present invention, a foamed thermoplastic elastomer layer serving as a skin material layer and a cushion layer, and a foamed thermoplastic resin layer serving as a substrate are integrally laminated, and are lightweight and excellent in soft feeling. In addition, it is possible to easily obtain a laminate having good appearance and capable of freely responding to various design properties. The laminate thus obtained can be suitably used particularly for automobile interior parts, for example, door trims, instrument panels, pillar trims, console boxes, seat backs, and the like.

[0042]

EXAMPLES The present invention will be specifically described below, but it goes without saying that the present invention is not limited to these examples.

Example 1 A male mold (A) and a female mold (B) for forming a foamed base material layer as shown in FIGS. 1 and 5 capable of forming a box-shaped product having a product outer dimension of 300 × 250 × 30 mm. Using a female mold (C) for molding a cushion layer, a foamed thermoplastic elastomer layer (thickness 6 mm) as a cushion layer and a thermoplastic elastomer sheet of a skin material are formed on a foamed thermoplastic resin base layer (thickness 4 mm). (Thickness: 0.6 mm) was integrally laminated.

The thermoplastic resin used as the base material is a propylene resin (Sumitomo Noblen AZ864E4, MFR = 30
g / 10 minutes, manufactured by Sumitomo Chemical Co., Ltd.) and 2 parts by weight of an inorganic chemical foaming master batch MB3074 (manufactured by Sankyo Chemical Co., Ltd.) was blended with 100 parts by weight of this propylene resin. As the thermoplastic elastomer to be the cushion layer, a polyolefin-based thermoplastic elastomer (Sumitomo TPE3782, manufactured by Sumitomo Chemical Co., Ltd.) made of polypropylene and ethylene-propylene copolymer rubber is used.
Parts by weight of inorganic chemical foaming masterbatch MB3074
2 parts by weight (manufactured by Sankyo Chemical Co., Ltd.) were blended. As the skin material, an olefin-based thermoplastic elastomer sheet (TPO) (manufactured by Kyowa Leather Co., Ltd.) having a thickness of 0.6 mm and having a textured surface on the surface was preformed into a product shape by vacuum forming.

Using a female mold (B) for forming a base layer having a male mold (A) and a movable block (5) operated by hydraulic pressure in the mold (FIG. 1), a foamed base material layer was formed. . The female mold (B) and the male mold (A) for forming the base material layer are brought close to each other so that the gap between the male and female molds becomes a predetermined cavity clearance. Is heated to 200 ° C. from the first molten resin supply port (3) while being moved forward from the female mold (B) so as to cover the second molten resin supply port (4) provided in the male mold. The molten propylene resin containing the blowing agent is supplied into the cavity (6) (FIG. 2), and the female mold (B) is further lowered to fill the cavity with the propylene resin containing the blowing agent. Tightened. At this time, the thickness of the blowing agent-containing molten propylene resin layer was 2 mm. (Fig. 3)

After pressurizing for 3 seconds in this state, the female mold (B)
Was raised by 2 mm to foam an unfoamed molten propylene resin layer still in a molten state, and cooled in this state to obtain a foamed base material layer (9) having a thickness of 4 mm (FIG. 4).

After the cooling of the foamed base material layer is completed, the movable block is retracted, and the female mold (B) for forming the base material layer is raised while the foamed base material layer (9) is held in the male mold (A). After removal, the female mold (B) was replaced with a female mold (C) for forming a cushion layer.

A preformed TPO skin material (11) is set on the cavity surface of the female mold (C) for forming the cushion layer, and the slide block (10) is operated toward the center of the mold by operating the slide block (10). The skin material is held (FIG. 5). The female mold (C) for forming the cushion layer is lowered so that the clearance between the male and female molds becomes a predetermined clearance, and the penetration formed in the foamed base material layer from the second molten resin supply port (4). The molten thermoplastic elastomer containing a foaming agent is supplied between the skin material (11) and the foamed base material layer through the holes (12) (FIG. 6), and the female mold (C) is further lowered to melt the foamed agent-containing molten heat. The plastic elastomer was shaped into a thickness of 3 mm, and at the same time, the skin material (11) and the foamed base material layer (9) were integrally laminated (FIG. 7).

After maintaining the pressure in this state for 3 seconds, the female mold (C) was raised by 3 mm, and the unfoamed molten thermoplastic elastomer layer still in the molten state was foamed. While maintaining this state, the inside of the mold is cooled until the thermoplastic elastomer layer solidifies, and the foamed polypropylene base layer (4 m thick) is formed.
m), foamed thermoplastic elastomer cushion layer (thickness 6 mm) and TPO skin material (thickness 0.6 mm)
Were obtained (Fig. 9). The obtained laminate had a good soft feeling without any appearance defect.

Comparative Example 1 A laminate was obtained in the same manner as in Example 1 except that the 3 mm-thick molten thermoplastic elastomer layer laminated on the foamed base material layer was cooled in a mold without foaming. .
The obtained laminate had a good appearance but lacked a soft feeling. Comparative Example 2 A laminate was obtained in the same manner as in Example 1 except that the skin material (11) was not set in the female mold (C) for molding a cushion layer. Although the obtained laminate had a soft feeling, a streak-like appearance defect occurred on the surface.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of an example of a mold used for molding a foamed base material layer of a laminate used in the method of the present invention.

FIG. 2 is a schematic cross-sectional view of a mold showing a process for producing a foamed base material layer of a laminate according to the method of the present invention.

FIG. 3 is a schematic cross-sectional view of a mold showing a process for producing a foamed base material layer of a laminate according to the method of the present invention.

FIG. 4 is a schematic cross-sectional view of a mold showing a process for producing a foamed base material layer of a laminate according to the method of the present invention.

FIG. 5 is a schematic sectional view of an example of a mold used for forming a cushion layer of a laminate used in the method of the present invention.

FIG. 6 is a schematic cross-sectional view of a mold showing a step of manufacturing a cushion layer of a laminate according to the method of the present invention.

FIG. 7 is a schematic cross-sectional view of a mold showing a step of manufacturing a cushion layer of a laminate according to the method of the present invention.

FIG. 8 is a schematic cross-sectional view of a mold showing a step of manufacturing a cushion layer of a laminate according to the method of the present invention.

FIG. 9 is a schematic sectional view of an example of a laminate obtained by the method of the present invention.

[Explanation of symbols]

 A: Male mold B: Female mold for base material layer molding C: Female mold for cushion layer molding 1: First molten resin passage 2: Second molten resin passage 3: First molten resin supply port 4: Second 5: Movable block 6: Mold cavity 7: Molten thermoplastic resin containing foaming agent 8: Molten thermoplastic resin layer containing foaming agent 9: Foaming base material layer 10: Slide block 11: Skin material 12 : Through hole 13: Molten thermoplastic elastomer containing foaming agent 14: Molten foamed thermoplastic elastomer layer 15: Foamed thermoplastic elastomer layer 16: Laminate

Claims (3)

[Claims] 1. A first molten resin supply port for supplying a molten foamed thermoplastic resin serving as a base material layer, and a second molten resin supply for supplying a molten foamed thermoplastic elastomer serving as a cushion layer. Using a male mold (A) having a mouth, a female mold (B) for molding a base layer, and a female mold (C) for molding a cushion layer, a foam cushion layer made of a thermoplastic elastomer is welded and integrated to the skin layer. And a method for producing a laminate in which the foamed cushion layer and the foamed thermoplastic resin layer serving as a base material are welded, laminated and integrated, (1) formed by a male mold (A) and a female mold (B). The blowing agent-containing molten thermoplastic resin is supplied from the first molten resin supply port into the cavity to be filled, and the foaming agent-containing molten heat corresponding to the position of the second molten resin supply port is simultaneously filled into the cavity. Penetrates in the thickness direction of the plastic resin layer Step of forming a through hole (2) After completion of shaping, the male and female molds are opened in a state where the blowing agent-containing molten thermoplastic resin is not solidified, and the blowing agent is contained while maintaining the state in which the through hole is formed. Step of foaming the molten thermoplastic resin (3) Step of cooling and solidifying the foamed thermoplastic resin layer in the mold (4) With the foamed thermoplastic resin layer held in the male mold (A), Step of removing the female mold (B) and replacing it with a female mold (C) for forming a cushion layer in which the skin layer is held in the mold product shape part (5) The foamed thermoplastic resin layer and the cushion held in the male mold (A) Into the cavity formed from the skin layer held by the female mold for layer molding (C), the through hole formed in the foamed thermoplastic resin layer from the second molten resin supply port of the male mold (A). Supplying the blowing agent-containing molten thermoplastic elastomer through the holes, A step of welding and laminating the skin layer and the foamed thermoplastic resin layer together with the thermoplastic elastomer while filling the cavity, and (6) after the shaping is completed, the foaming agent-containing molten thermoplastic elastomer which becomes a cushion layer In a state where is not yet solidified, the male mold (A) and the female mold (C) for forming the cushion layer are opened, and the step of foaming the molten thermoplastic elastomer is performed. (7) The mold is opened after cooling and solidifying, A method for producing a laminate, comprising a step of removing a laminated molded product from a mold. 2. A method in which a blowing agent-containing molten thermoplastic resin and / or a blowing agent-containing molten thermoplastic elastomer is supplied in a state where both male and female molds are not closed, and the mold is closed to fill the cavity. The method for producing a laminate according to claim 1, wherein: 3. The method according to claim 1, wherein the thermoplastic elastomer is an olefin-based elastomer.